Suzuki GS125, GS125ES, GN125, GZ125 Marauder, DR125S Repair Manual 1982-2005

The 1982-2005 Suzuki GS125, GS125ES, GN125, GZ125 Marauder, DR125S repair manual by Haynes covers the following street motorcycle models:

• Suzuki GS125, 1982-1987
• Suzuki GS125ES, 1982-2000
• Suzuki GN125, 1993-2001
• Suzuki GZ125 Marauder, 1998-2005
• Suzuki DR125S, 1982-2001

Book Excerpt: 1982-2005 Suzuki GS, GN, GZ Marauder, DR 125 Repair Manual ENGINE, CLUTCH AND GEARBOX

EXAMINATION AND RENOVATION: CRANKSHAFT ASSEMBLY

1. The most likely areas of crankshaft failure are as follows. Main bearing failure, accompanied by a low rumbling noise as the engine is running, or big-end bearing failure, accompanied by a pronounced click or knock from the crankcases. In both the above cases the noise will increase gradually and will be accompanied by increasingly severe levels of vibration which will be felt through the frame and footrests. Excessive wear in the small-end bearing is revealed by an annoying light metallic rattle. Crankshaft wear is unlikely to take place until a very high mileage has been covered, or unless routine maintenance, in the form of regular oil and filter changes has been neglected.
2. Wash off the crankshaft to remove all traces of oil, then make a close visual inspections of the assembly, using a magnifying glass if necessary. If any obvious signs of damage are encountered, for example bent or distorted mainshafts or connecting rod, cracks or nicks in the connecting rod, damaged mainshaft threads, worn keyways or damaged cam chain sprocket teeth, take the assembly to a good Suzuki dealer for his advice; some damage may be reclaimed whereas in other cases the only solution will be the renewal of the crankshaft assembly.
3. Check for wear in the big-end bearing by arranging the connecting rod in the TDC position and by pushing the pulling the connecting rod. No discernible movement will be evident in an unworn bearing, but care must be taken not to confuse end float, which is normal, and bearing wear. If a dial gauge is readily available, a further test may be carried out by setting the gauge pointer so that it abuts against the upper edge of the periphery of the small-end eye. Measurement may then be taken of the amount of side-to-side deflection of the connecting rod. If this measurement exceeds the service limit of 3.0 mm (0.12 in) then the big-end bearing must be renewed.

WHEELS, BRAKES AND TIRES

BLEEDING THE HYDRAULIC BRAKE SYSTEM

1. If the brake action becomes spongy, or if any part of the hydraulic system is dismantled (such as when a hose is replaced) it is necessary to bleed the system in order to remove all traces of air. The procedure for bleeding the hydraulic system is best carried out by two people.
2. Check the fluid level in the reservoir and top up with new fluid of the specified type if required. Keep the reservoir at least half full during the bleeding procedure; if the level is allowed to fall too far air will enter the system requiring that the procedure be started again from scratch. Refit the reservoir cover to prevent the ingress of dust or the ejection of a spout of fluid.
3. Remove the dust cap from the caliper bleed nipple and clean the area with a rag. Place a clean glass jar below the caliper and connect a pipe from the bleed nipple to the jar. A clear plastic tube should be used so that air bubbles can be more easily seen. Place some clean hydraulic fluid in the glass jar so that the pipe is immersed below the fluid surface throughout the operation.
4. If parts of the system have been renewed, and thus the system must be filled, open the bleed nipple about one turn and pump the brake lever until fluid starts to issue from the clear tube.

Subject: 1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005 Suzuki GS125, GS125ES, GN125, GZ125 Marauder, DR125S service, maintenance, repair. ISBN-10: 1844252787 | ISBN-13: 9781844252787 | Haynes 0888